Modern textile testing and quality control equipment

Modern textile testing and quality control equipment:

Quality: Quality is the attribute of the products that determines its fitness for use, or according to Japanese Standard (JIS), textile (fibre, polymer, yarn, fabric) quality is all specific properties and performance of a textile product or service that can be evaluated to determine whether a product or services satisfactorily meets the purposes of its uses. The level of quality is measured by “ inherent properties and performances which is the subjects of evaluation or the characteristic related to its phsico-mechanical or chemical properties, dimension, longevity, durability utilization or any other requirement used to define the of the product or service is known as “quality characteristics”.

Standard: It is an agreed document established mainly with respect to technical matters related directly or indirectly to an article or service. So that profit or convenience may be obtained with fairness among the person concerned.

Testing:  The way to control or the way to check or verify the nature & characteristics. Or, the way to checking or verifying.

Modern Fibre or Polymer Quality Testing Equipment:

Fibre characteristics must be classified according to a certain sequence of importance with respect to the end product and the spinning process. Moreover, such quantified characteristics must also be assessed with reference to the following

• What is the ideal value?

• What amount of variation is acceptable in the bale material?

• What amount of variation is acceptable in the final blend?

Textile fibre contains some basic characteristics. 

Following are the basic characteristics of cotton fibre

• Fiber length

• Fineness

• Strength

• Maturity

• Rigidity

• Fiber friction

• Structural features

Name Of The Machine for fibre testing and quality control	Function of the Fibre/ Polymer Quality testing machine
1.HVI (High Volume Instrument)	It’s a very popular fibre characterization and quality testing machine in USA, UK, China, Korea and other countries. It is very cause sensitive and provides perfect fibre quality testing result. 50% span length, 2.5% span length, Uniformity ratio, Mic value, Color grade, Maturity ratio, gm/tex (tenacity), SFI (Short Fibre Index) etc. Suitable for knitted yarn production.
2.AFIS (Advance Fibre Information System)	It is also popular fibre testing machine and very cause sensitive and provides perfect fibre quality testing result. 50% span length, 2.5% span length, Upper half length, Trash%, Neps, Seed coat neps both in number & weight, short fibre content, Maturity ratio, fibre strength etc. Suitable for export woven fabric production.
3.Digital Fibre Graph	It is also popular fibre quality testing equipment and used to measure 50% span length, 2.5% span length, Uniformity ratio.
4.Digital Moisture meter	It is also popular fibre quality testing equipment and used to measure Directly Moisture content % is determined.
5.Trash Selection	It is also popular fibre quality testing equipment and used to measure Trash% in raw cotton is found out.
6.Sling Hygrometer	It is also popular fibre quality testing equipment and used to measure Directly RH% is measured.
7.Precision Polarizing Microscope	Ihis type of testing machine is used for Fibre identified with digital photographs, maturity ratio.
8.Stetometer with Torsion Balance	Bundle fibre strength is measured by this testing machine.
9.Instron	This type of testing machine is rear in used. Single fibre strength is measured (research based) by this testing equipment.

Modern Yarn Quality Testing Equipment:

Yarn is a main element for textile production. Good yarn contains some characteristics. The main characteristics are strength, elongation, hairiness, uniformity, diameter etc.

Name Of The Machine for yarn testing and quality control	Function of the Yarn Quality testing machine
1.Uster Evenness Tester 4&5	This yarn quality testing equipment is used to measure U%, CV%, Imperfection (Thick place /1000m, Thin place/1000m, Neps /1000m), Irregularity index, Relative count, hairiness etc. In case of UT-5 polypropylene content in yarn is also determined recently.
2.Uster Tenso Jet	This yarn quality testing equipment is used to measure  Single yarn strength & Elongation% is determined.
3.Uster Tenso Kind	This yarn quality testing equipment is used to measure Lea strength, Breaking force, Elongation% determined.
4.Uster Tenso Rapid	This yarn quality testing equipment is used to measure Single yarn strength, Lea strength & Fabric strength, Elongation% is determined.
5.Uster Classimat	This yarn quality testing equipment is used to measure Yarn fault in category wise determined (23-27 categories).
6.Auto Cone Winder	This yarn quality testing equipment is used to measure Auto splicing, Slubs removes in running m/c.
7.Uster Auto Sorter	This yarn quality testing equipment is used to measure Rapidly Yarn count, Sliver/Roving hank etc

Modern Fabric Quality Testing Equipment:

Textile fabrics are made for various purpose, each of which has different performance needs. The chemical and physical states of textile fabric identify what will the end use of this, and ultimately whether it is reasonable for a specific use. Fabric testing makes a crucial role in gauging product quality, ensuring regulatory compliance and assessing the perfection of textile materials. It provides information about the physical or structural, chemical and performance properties of the textile. As user become more aware and more demanding of products, the number of tests required for textile fabrics has grown. As a result the testing of fabrics is increasingly varied, in constant flux and full of the unprecedented challenges of globalization. With the onset of modern types of fabrics for the garments factory and of technical textiles for functional applications, and with the growing number of invention taking place in the apparel sector, fabric testing processes have undergone tremendous changes and there is required to realize all the procedures before a testing method is involved to investigate the performance of fabrics. 

Name Of The Machine for fabric testing and quality control	Function of the Fabric Quality testing machine
1.Automatic Pick Counter	Ends/inch & Picks/inch is digitally measured.
2.Universal Titan	Fabric strength, Elongation with printed form.
3.Spectro Photometer/Data    Color	Pass/fail (quality if fabric), Recipe formulation, Grey scale value, Whiteness value, Shade% etc is determined.
4.Wascator	Shrinkage% is determined by programming.
5.Martindile Abrasion &    Pilling tester	Abrasion resistance as well as pill formation on the fabric is determined.
6.Seam Slippage Tester	Seam strength & Elongation % is determined.
7.GSM Cutter with Balance	GSM of the fabric is measured.
8.Color dispenser	Automatically stock solution is prepared according to Programming.
9.Megasol	Light fastness of the dyed fabric is determined digitally.

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Process Wise Quality Defected Point of garments in appeal garments industry

There are many defects introduced to produce a garment in garments industry. The operator of garments pressured to produce a garment by the supervisor. That’s why it is possible to make any quality defects. This quality defects could be classified as critical defect, major defect and minor defect. Critical defect of garments could be summarized as those defective goods that do not comply with buyer’s safety requirements for babies and children’s wear. The major defect of garments could be defined as the defect is noticeable to the customer and visible when using the goods. The defect is not noticeable to the customer and not visible when using it is known as minor defect of garments manufacturing. Only the process wise defect identified in the garments by garments quality controllers is described bellow.

1. Defects in shoulder joint of garments:
  -Curve at Shoulder.
  -Tension loose At Shoulder.
  -Tension Tight At Shoulder.
  -Needle Cut At Shoulder Joint & Top Stitch.
  -Dirty Spot At Shoulder.
  -Shading at Back & Front Part.
  -Thread Shading At Shoulder Joint & Top Stitch.
  -Puckering At Shoulder.
  -Tension Loose At Shoulder Joint.

2. Defects in Neck Rib Joint of garments:
  -Uneven At Neck rib Width.
  -Shading At Neck rib joint.
  -Broken stitch at neck Rib joint.
  -Skip /Drop Stitch At Neck Joint &Top Stitch.
  -Puckering at neck Rib joint.
  -Pleated at neck Rib joint.
  -Needle Cut/ hole at neck Rib joint.
  -Center Out At Main/Size Label.
  -Not Position At Care Label.
  -Size Mistake At Size Label.
  -Tension Loose At Neck Rib Joint.                           

3. Defects in Sleeve joint and Top stitch of garments:
  -Size Mistake At Sleeve.
  -Pleated at Armhole.
  -Needle Cut/ hole at sleeve joint.
  -Shape uneven at sleeve joint.
  -Skipped stitch at sleeve joint.
  -Up-Down at sleeve joint.
  -Up-Down at under Arm Length.
  -Un-Even at arm hole top Stitch.
  -Shading At Sleeve /Back/Front Part.
  -Dirty Spot At Sleeve/ Back & Front Part.
  -Oil Spot At Sleeve /Back & Front Part.
  -Bundle Mistake At Sleeve Back& Front Part.
  -Tension Loosen At Sleeve Joint /Topstitch.

4. Defects in Side Seam of garments:
  -Curve at side Seam.
  -Needle Cut/Hole At Side Seam.
  -Dirty Spot At Side Seam.
  -Oil Spot At Side Seam.
  -Broken stitch at side seam.
  -Drop/Skip stitch at side seam.
  -Up-Down at Armhole Point.
  -Uneven At Side Top Stitch.
  -Tension Loose At Side Seam.

5. Defects in Body Hem & Sleeve Hem of garments:
  -Broken stitch at body Hem.
  -Uneven At Body hem.
  -Needle Cut/Hole At Body Hem.
  -Raw Edge At Body Hem.
  -Skip/drop stitch at body Hem.
  -Dirty / Oil spot at body & sleeve Hem.
  -Tension Loose At Body/Sleeve Hem.

6. Defects in Cuff joint make & Top stitch of garments:   
  -Skip / Drop at cuff make stitch.
  -Uneven at cuff topsin/ top stitch.
  -Uneven At cuff joint.
  -Point Up-Down at cuff joint.
  -Skip/ Drop at cuff joint top Stitch.
  -Shape uneven at cuff.
  -Size mistake at cuff.
  -Pair Mistake at cuff.
  -Oil Spot At Cup.
  -Dirty Spot At Cup.
  -Tension Loose At Joint/Top stitch.

7. Defects in Collar Joint Top sine & Make of garments:
  -Drop stitch at collar make /joint/ Top stitch.
  -Up-Down at collar point.
  -Uneven at notch point.
  -Up-Down at hala point.
  -Uneven at band top stitch.
  -Uneven at collar shape.
  -Tension Loose At Collar Joint/Make/ Top stitch.
  -Drop Stitch At Band Top stitch.                                       

8. Defects in Placket Joint & Topsin (Top stitch) of garments:
  -Slanted at Placket joint.   
  -Placket is not middle on garments.
  -Up-Down at Placket notch.
  -Uneven at Placket box.
  -Displace at button.
  -Tension Loose At Placket Joint & Topstitch.
  -Dirty Spot At Placket.
  -Oil Spot At Placket.

9. Defects in Button holing and button attach of garments:
  -Half stitch at button.
  -Fals stitch at button.
  -Insiquite button.
  -Reject at button.
  -Style Mistake At Button.
  -Tension Loose At Button Stitch.
  -Spot On Button.

10. Defects in Shoulder to Shoulder Back Tape of garments:   
  -Lop uneven at back tape.
  -Not Middle at back tape top stitch.
  -Broken stitch at back tape.
  -Drop stitch at back Tape.
  -Raw edge at back Tape.
  -Spot On Back Tape.                                        

11. Others Defect Point in Garments:
  -Running shade On Fabrics.
  -Yarn Contaminated On Fabrics.
  -Crease / Dia mark On Garments.
  -Back part Front part shade.
  -Slanted at V point.
  -Raw Edge at bottom.
  -Raw edge at sleeve hem.
  -Up Down at loop.
  -Displace at GSM  Hi-Low.
  -Ties Up –Down.
  -Uncut Thread.
  -Shading at Thread.

11. PC / Trim Card Follow:
  -Bulk Production time M/B follow this PC Card.
  -Fabric Color Check.
  -Thread Color Check.
  -Care, Main & Size label Check.
  -Twill Tape Check.
  -Mobilon tape Check.

12. Machine Adjustment:
  -Bulk Production time all machine S/B Adjust.
  -Machine Adjustments is the main subject make your good Garments.
You con read RELATED TOPICS for more information.
Garments defects and production procedure...........................

PRODUCTION MANAGEMENT SYSTEMS IN TEXTILE INDUSTRY

Production management system in textile industry is very much important term. Proper production management system ensure the production quality, production time and production costs. A well skilled production management system ensures quality product according to byres requirements.  The presence, in factories, of highly intelligent, local control systems has favored the development of production management systems. Nearly all process controller producers also offer surveillance systems that centralize data relating to checks carried out on the machine and allow various levels of interaction in production management system. There is now a very wide range of production management software functions available, and new developments are emerging all the time in various areas as a result of greater contact between software designers and users in the textile sector.
These areas include:
- Production planning
- Planning of production start-up (availability, requirements in terms of human resources and machines, etc.)
- Production Management of dyeing and finishing cycles
- Plant and single machine surveillance, remote acquisition and saving of key physical parameters, log record of alarms
- Plant and machine synoptic alarms (sometimes interactive)
- Records of orders and work carried out of production
- Recipe and cycle sequence management
- Management of dyestuffs and auxiliaries warehouse
- Statistical analysis of production
- Quality control-based classifications
- Tracking of single batches, i.e., the keeping of records of the different dyeing and finishing stages so as to make it possible in the future, in the event of disputes or problems, to trace the history of a piece
- Link-ups with ERP systems, for the transmission of data relating to technical operations of interest to the accounts department.

The application of information technology to production in the textile sector is similar, in many regards, to its application in most other manufacturing sectors of textile or apparel factory.
In particular:
• Information technology is taken out of the IT centre, and distributed throughout the mill, making it possible to present/access data wherever they are needed or generated for production management;
• Purely administrative functions are supported, more and more, by out-and-out automation functions: management and processing of organizational-type data, but also technological data relating to production of factory;
• Batch processes (data processing operations carried out by the computer at the end of which one obtains: balance sheets, production plans, warehouse status, etc.) are replaced by real-time applications, which make it possible, through one of the terminals linked up with the computer, to access and update records immediately;
• There is a growing need to integrate the processing of information relating to areas that are distinct from, but connected with, one another: design, technological definition of processes, machine preparation, planning of resources, etc.

Textile companies want the adoption of IT systems in the production environment to generate a greater and greater rationalization of production management system, and to reduce errors and waste in textile industry. The requirements of a textile company, as regards its information system, can be broken down into three areas:
1. Company management: at this level, information systems are needed for the working out of production plans, the checking of results and the working out of sales and cost plans.

2. Function management: For function management system, they are required to respond to the need to determine the production plan and flow. In particular, they help in the processing of orders, converting them into processing instructions for individual departments, stages or machines. They make it possible to optimize batches on the basis of resources and technological parameters, even simulating the production chain so as to optimize production speeds and balance workloads among machines.

3. Process management: For process management system, they serve to tune the numerous technical regulation and programming procedures that are involved in the production process. In this stage, information systems make it possible to gather all the basic data needed for control and function planning activities.

Benefits of production management system
 -Integration of different areas (resource planning, designing, recipe preparation, machine programming, cost control)
 -Better customer service in terms of order status and delivery times (shorter)
 -Reduction of errors
 -Increased company flexibility
 -Greater control over the company’s overall activity
 -Reduction of stocks
 -Reduction of downtime
 -Process repeatability

Limitation of production management system
 -Modification of the modus operandi (which results in the need to standardize procedures and train staff)
 -Standardization problems (due to control systems that are often incompatible with one another)
 -Poor product customization

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